8-Gear BoxAssembly line mapUnionaire Group is the one of many companies growing in the field of home appliances manufacturing and distribution.Union aireUnionaire group products:1- Air conditioning2- Cook stove3- TV4- Water Filter 5- Washing machineThe washing machine line has been established 5 years ago since 2007.The production rate last year at 2012 reached to 220 000 washing machines as a total production locally and abroad.The rate of production increased during the past 3 years by a percentage of 70 – 80 %.Plant CapacityProcess map ChartAssembly line mapProduction line VideoMany non-value add activities has been founded in the production lineNon-add Value activityAssembly hotspotsHotspotsElectricity hotspotsInspection hotspotsElectricity Stage.Upper frame isolation. Mechanical Seal compression. Water leakage.Ranking the hot spots to find the bottleneck of the production lineA Pareto chart was applied to identify the bottleneckWaitingWaitingSeven WastesWaitingSeven WastesWaiting for the next production step, Worker wait to work on the washing machine.Waiting waste descriptionBecause of the farness between the warehouse and production line that could make a shortage of the raw material.

It could cause a delay in time so we decided to develop “ Andon system”Andon System

Andon System can send a signal from the production line to warehouse manager before any shortage of the material to have enough time to prepare and send it.

Andon System can save the worker cost and the delay cost.Andon System Bill of material “Andon system “Andon system could improve and prevent the waiting for material that come from inventory before finishing it .Andon was a general improvement in the production line.Waiting WasteFound In four processes :Spin Tub, Body, Base, Electricity and Water leakageThis process is the longest process all over the production line .

Isolation bags.Components of electric circuitBefore improvement :After improvement :Some Shoots from Solid works software for Socketprototype for the Socket methodologyWorkers or Washing machine moving or walking more than is required while performing the processing. found :

1- Spin Motors

2- washing Motors,

3- Upper frame isolation,

4- Spin Tub Fixation,

5- Upper Frame Fixation ,

6- Polishing and PackagingExcessive MotionNew design for the plate make the washing machine moves over the conveyer

Around part to make the movement of washing machine is too easy to worker .Solution Of Motion WasteCarouselworkers are moving randomly.

Cause: No place behind them to store material , MovingTransportationNew design in the layout a new space behind the worker

Use another worker to deliver the bodies to worker on mechanical seal press.Solution(Resulting from poor tool or product design creating activity)Found: Upper frame isolation : the worker has to cut and uncover the foam tape before using it.Electricity : workers have to join the wire with his bare hands.Over-processesElectricity process Socket.

Upper frame Isolation process add another worker to uncover the foam tape to preventing.Solution(The effort involved in inspecting for and fixing defects)

no defect washing machine pass through the quality section

may be some parts of the washing machine had a defect

It’s not a big problem because reworking in less timeDefect(Producing washing machine more than is needed).

But this waste isn’t found because the company wants to produce. more than it’s production rate to cover the market needs.OverproductionSeven waste MatrixPie Chart for seven waste matrixworkplace organizational tools that provide the necessary groundwork for workplace improvement.

Current layout of the production line.

Proposed layout after implementing 5s.5S Visual ControlsCurrent layout of the production line.S1 = Sort“Separate things which you need from things you don’t need”Observation was:

1- Useless waste of material, scrap, semi-finished washing machines, spares parts on the floor that can prevent the ease of motion

2- Additional supporting material left behind the workers

3- Water on the ground after the process of water inspection.S1S2 =Set in Order“Keep conditions which allow you to easily access what you need, when you want”.

5- There are no designated areas for eating and smoking.S4S5=Sustain“Make a habit of obedience to the rules”Observation was: 1- The Safety department doesn’t provide complete safety clothing such helmets safety shoes.S5Clean the floor continuously.

Remove the scrap material .

Set a maintenance plan to avoid any cracks or drops.

Must indicate the maximum and minimum allowable quantities.

Cleaning and fixing the lighting system continuously.

Hiring one person to be responsible for overseeing the process.Suggestions to avoid these problems and fixed itUsing the moderate method to store the raw material “ Motors, Gear Box Base And Bodies “ by using Shelving and bins.

Shelving and bins - horizontal platforms in structural frame that Steel shelving comes in standard size.Proposed layout after implementing 5sindicators for production lineLean MetricsNow implementing Lean was finished let’s go to see the resultProposed VSM Lead time changed processes were changed in time because of our improvement Six VSM was drawn: 1- Over View Map

2- Assembly Line

3- Body preparation

4- Base preparation

5- Electricity Line

6- Inspection LineResultElectricity Process Before and After ImprovementconclusionsLead time changed from 28.5 min to 20.3When a 380 washing machine was produced in 6.5 hours per day in lead time 28.5 > now 20.3So 380 washing machines will be produced 4.6 hours.The takt time was 61 second .Production:

(1.9*60*60) Sec / 61 sec= 113 washing machines or more per shift .

The Profit in one washing machine 200 L.E , then it will be In 113 washing machine is =113*200 =22, 600 L.E.Production rate become approximately 493 Washing machineBefore Anodon system production line could stop about 2 hours getting material from inventory .

2 hours could reduce its production rate to 263 washing machines per shift and it could cause a loss in profit 23,400 L.E.Recommendation-Continues elimination of waste that appear after application of this project (continues improvement).

-Applying this study to other washing machine appliance production lines in the factory.

-Applying another tools of lean manufacturing such as: Kanban, Kaizen.

-more intensive time analysis should be taken in considerations as a next turn of improvement .